Maintenance and Troubleshooting
Contents
1. Base jumper s connect logic ground and chasis ground on CPU terminal strip Optional CPU jumper connects logic ground and chassis ground DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 9 17 Machine Startup and Program Troubleshooting The DL405 CPUs provide several features that can help you debug your program before and during machine startup This section discusses the following topics which can be very helpful e Program Syntax Check e Duplicate Reference Check e Test Modes e Run Time Edits e Special Instructions Syntax Check Even though the Handheld Programmer and DirectSOFT provide error checking during program entry you may want to check a program that has been modified Both programming devices offer a way to check the program syntax For example you can use AUX 21 CHECK PROGRAM to check the program syntax from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT This check will find a wide variety of programming errors The following example shows how to use the syntax check with a Handheld Programmer Use AUX 21 to perform syntax check CLR AUX 2 1 ENT ENT AUX 21 CHECK PROGRAM 1 SYN 2 DUP REF Select syntax check 1 ENT This may take a minute or so Ho BUSY One of two displays will appear Erro2. CPU W E COM A N N N N O e Seer oo oOacjcococ aS 22 5 5 5 2 no EO oooQelea Sel c 25 a m an a Ser gO Incorrect module SF Ze S E252 NEW I O CFG Program Control Information V7752 0028 Current module ID code V7753 0026 Current module ID code V7754 0002 Location of conflict V7756 0252 Module Error Code SP45 F I O abnormality DL405 User Manual 4th Edition Rev A 9 7 Maintenance and Troubleshooting Error Message The DL440 and DL450 CPUs will automatically log any system error codes and any Tables custom messages you have created in your application program with the Fault Xl Viv instructions See Chapter 11 for details on the Fault instruction The CPU logs the 430 440 450 error code the date and the time the error occurred There are two separate tables that store this information e System Error Table stores up to 32 errors in the table e Fault Message Table stores up to 16 messages in the table When an error or message is triggered it is put into the first available table location Therefore the most recent error message may not appear in the first row of the table If the table is fu
3. e 1 O configuration error on modules such as analog I O high speed counting specialized communications and so on e A blown fuse in your machine or panel the DL105 does not have internal I O fuses e A loose terminal block e The auxiliary 24 VDC supply has failed e An Input or Output point has failed Some Quick Steps When troubleshooting the DL series I O modules there are a few facts you should be aware of These facts may assist you in quickly correcting an I O problem e The output modules cannot detect shorted or open output points If you suspect one or more points on a output module to be faulty measure the voltage drop from the common to the suspect point Remember when using a Digital Volt Meter leakage current from an output device such as a triac or a transistor must be considered A point which is off may appear to be on if no load is connected to the point e The I O point status indicators on the modules are logic side indicators This means the LED which indicates the on or off status reflects the status of the point with respect to the CPU On a output module the status indicators could be operating normally while the actual output device transistor triac etc could be damaged With an input module if the indicator LED is on the input circuitry should be operating properly Verify the LED goes off when the input signal is removed e Leakage current can be a problem when connecting field devices to I O modules Fal
4. x3 C Y1 G3 C amp D STOP Instruction Sometimes during machine startup you need a quick way to turn off all the outputs and return to Program Mode In addition to the Test Modes you can also use the STOP instruction When executed a STOP causes the CPU to exit Run Mode and enter Program Mode The following program does this Remember all outputs are turned off during Program Mode X10 X4 1 4 ouL LusJuUeN v 2 3 SE D 2 gt fe A amp Normal Program STOP puts CPU in Program Mode XO X2 YO X20 CO mp T0 X1 X3 X4 xo x2 Yo 1 4 C3 X10 a1 x1 X3 X4 C 1 4 17 I X10 Y1 Eno C eD DL405 User Manual 4th Edition Rev A fe Z o OO cc oa 52 Fa es oo SF ko ta oO Maintenance and Troubleshooting BREAK Instruction If you have a DL440 CPU you can also use the BREAK instruction to stop the program scan As long as the BREAK instruction is active the scan is stopped and the CPU enters a special mode TEST HALT You have to use either the Handheld Programmer or DirectSOFT to restart the scan by placing the CPU back in Run Mode When the CPU returns to Run Mode the scan resumes at the point of the break For example if you are using several data instructions it may be helpful to stop the scan and examine the accumulator
5. e A grounding difference exists between the two devices 2 e Electrical noise is causing intermittent errors 5 e The CPU has a bad communication port and the CPU should be Sg replaced D 7 If an error occurs the indicator will come on and stay on until a successful 2a communication has been completed If the cable and its connections are OK try ga doing a power cycle on the devices at both ends of the communications cable a TXD and RXD The TXD and RXD indications on the DL450 CPU work like the identically named Indicators LED indicators found on modem devices The TXD and or RXD indicators turn ON X XI Vv whenever the CPU either transmits or receives data respectively If the indicator s 430 440 450 remain off when you are expecting communications there is a problem The TXD and RXD indicators turn on when data is transmitted on any of the four ports on the DL450 Therefore when DirectSOFT or a HPP or an operator interface such as the DV 1000 is connected the TXD and RXD are on constantly If you are trying to detect communications originated by the ladder program itself it may be useful to disconnect the programing device or operator interface In this way only the cable for the communications you are debugging is connected DL405 User Manual 4th Edition Rev A 9 14 Maintenance and Troubleshooting I O Module Troubleshooting Possible Causes If you suspect an I O error there are several things that could be causing the problem
6. These memory references are in the form of V memory and SPs special relays The following two tables name the specific memory locations that correspond to certain types of error messages The special relay table also includes status indicators which can be used in programming For a more detailed description of each of these special relays refer to Appendix D DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting V memory Error The following table names the specific memory locations that correspond to certain Code Locations types of error messages Error Class Error Category Diagnostic V memory Minor Battery Voltage DL450 V7746 System 10ms calender timer DL440 450 V7747 User defined Fault message error code V7751 I O configuration Current module ID code V7752 I O configuration Correct module ID code V7753 I O configuration Base number Slot number V7754 Fatal Error code V7755 Major Error code V7756 Minor Communications Error code V7757 Module Base number Slot number V7760 Module Error code V7762 Grammatical Address V7763 Grammatical Error Code V7764 Special Relays SP The special relay table also includes status indicators which can indicate errors For Corresponding to amore detailed description of each of these special relays refer to Appendix D Error Codes Startup a
7. be faulty If the voltage to the power supply is not correct the CPU may not operate properly if at all For a new installation on AC powered CPU versions first check the 110 220 VAC select jumper on the terminal strip of the CPU Ifthe 110 VAC selection shunt is not installed while using 110 VAC you will see the following symptoms e The communication ports will not function e The CPU will only operate when no modules are installed If the 110 VAC selection shunt is installed while using 220 VAC the power supply in the CPU will be damaged If this has happened you will need to replace the CPU The best way to check for a faulty CPU power supply is to substitute a known good one to see if this corrects the problem If the jumper is correctly installed for the AC or DC version you are using then measure the voltage at the terminal strip to ensure it is within the CPU input specs It is possible a faulty module or external device using the system 5V can shut down the power supply This 5V can be coming from the base or from the top port on the CPU To test for a device causing this problem e Turn off power to the CPU e Disconnect all external devices example communication cables from the CPU e Reapply power to the system DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 9 11 If the power supply operates normally you probably have either a shorted device or a shorted cable Ifthe power supply does n
8. or off in the DL405 series CPUs but they cannot be forced in such a way to override ladder logic If you want to do an I O check out independent of the application program follow the procedure below Step Action 1 Change the CPU keyswitch to TERM Use a handheld programmer or DirectSOFT to communicate online to the PLC 3 Change to Program mode 4 Goto address 0 Insert an END statement at address 0 This will cause program execu 5 tion to occur only at address 0 and prevent the application program from running and turning I O points on or off Change to Run mode using the handheld programmer or DirectSOFT 2 We must do this to enable the outputs 7 Use the programming device to set turn on or off the points you wish to test 8 When you finish testing I O points delete the END statement at address 0 WARNING Depending on your application forcing I O points may cause unpredictable machine operation that can result in a risk of personal injury or equipment damage Make sure you have taken all appropriate safety precautions prior to testing any I O points ED X0 X2 X5 X7 YO Insert an END
9. AC select jumper incorrect on CPU terminal strip 2 External power is off or disconnected check fuses breakers 3 Power supply CPU is faulty 4 Other component such an I O module has power supply shorted 5 Power budget exceeded for the CPU being used RUN OFF 1 CPU programming error 2 Key switch in STOP position Flashing CPU is in firmware upgrade mode CPU ON 1 Electrical noise interference 2 CPU defective BATT ON or 1 Flashing at 2 Hz CPU battery low flashing 2 Flashing at 0 5 Hz Memory cartridge battery low DL440 DL450 only 3 On constantly Both the CPU and MC batteries are low 4 CPU or Memory cartridge battery missing or disconnected DIAG ON 1 The CPU internal diagnostics has failed 9 DL450 2 The local bus on the backplane has had a communications error Cz 1 0 ON 1 I O module failure 38 2 External power supply failure ot 3 Configuration error aS 4 Base expansion unit failure 3a o0 COM ON 1 Device port setup incorrect DL430 2 Cabling error DL440 3 Grounding problem 4 Electrical noise 5 Device port faulty TXD OFF 1 The CPU is not transmitting data on the secondary ports ports 1 2 DL450 and 3 due to programming error 2 The CPU is not in Run mode RXD OFF 1 External device is not transmitting to CPU secondary ports DL450 ports 1 2 and 3 2 Communications cable is defective or not connected DL405 User Manual 4th Edition Rev A 9 10 Maintenance and Troubleshooting PWR
10. D Ends the program FIND the Address OR NOT X IN 6 FIND O SEARCHING Insert the New Instruction AND X IN 7 SHFT INS sad J Q a5 o c3 co 05 nD 35 O0 a Co WANT TO INSERT Press CLR to abort the edit or ENT to accept ENT 8 If you press ENT the change is accepted ORN X 0006 and the next address is displayed If you pressed CLR the current address is displayed DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting Deleting an Deleting an instruction during Run Mode works almost exactly the same as it does Instruction During during Program Mode Remember this operation deletes the instruction that is Run Mode currently being displayed and the remaining addresses decrement Ladder Representation XO X2 X5 X7 YO ao our X1 X3 X4 Delete X7 X6 e Identify the Instruction ADDRESS INSTRUCTION DESCRIPTION 0 STR XO Starts branch 1 with XO 1 OR X1 Joins X1 in parallel with XO Delete 6 AND X5 Starts branch 4 with X5 7 AND X7 Adds X7 in series with X5 11 END Ends the program FIND the Address AND X IN 7 FIND SEARCHING fe Z o OO cc oa 52 Fa es oo SF ko ta oO Delete the Instruction SHFT DEL WANT TO DELETE Press CLR to abort the edit or EN
11. GRAM mode the CPU will not enter the RUN mode until the error has been corrected Examples of fatal errors e Power supply failure on the CPU base e Parity error or CPU malfunction e Certain programming errors Non fatal Errors Non fatal errors are errors that are flagged by the CPU as requiring attention They can neither cause the CPU to change from RUN mode to PROGRAM nor do they prevent entering RUN mode There are special relays the application program can use to detect if a non fatal error has occurred The application program can then be used to take the system to an orderly shutdown or switch the PLC out of RUN mode if needed Example of non fatal errors are e Battery backup battery voltage low e All I O module errors e Certain programming errors Finding Diagnostic Diagnostic information can be found in several places with varying levels of Information message detail e The CPU automatically logs error codes and any FAULT messages into two separate tables which can be viewed with the Handheld or DirectSOFT e The handheld programmer displays error numbers and short descriptions of the error e DirectSOFT provides the error number and an error message e Appendix B in this manual has a complete list of error messages sorted by error number fe Z o O OO cc OH 52 Fa es oo SF ko ta oO Many of these messages point to supplemental memory locations which can be referenced for additional related information
12. I O configuration These errors are captured in the System error attempts to transition to RUN mode log if they exist when the CPU Error Description Error Description Code Code E401 Missing END statement E431 Invalid ISG SG address E402 Missing LBL E432 Invalid jump GOTO address E403 Missing RET E433 Invalid SBR address E404 Missing FOR E434 Invalid RTC address E405 Missing NEXT E435 _ Invalid RT address E406 Missing IRT E436 Invalid INT address E412 SBR LBL gt 64 E437 Invalid IRTC address E413 FOR NEXT gt 64 E438 Invalid IRT address E421 Duplicate stage reference E440 Invalid Data Address E422 Duplicate SBR LBL reference E441 ACON NCON E423 Nested loops DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 9 9 CPU Status Indicators The DL405 CPUs have indicators on the front to help you diagnose problems with the system The table below gives a quick reference of potential problems associated with each status indicator Following the table is a detailed description of each indicator Bees eee Indicator Status Potential Causes PWR OFF 1 Power input voltage is incorrect for selected operating mode 110 220 V
13. Indicator Viviv 430 440 450 A OZD mee fe Z o OO cc oa 52 Fa es oo SF ko ta oO In general there are four reasons for the CPU or expansion unit power status LED PWR to be OFF 1 Power to the CPU is an improper voltage or the power range jumper 110 220 select does not match the power input voltage 2 CPU power supply is faulty 3 Other component s have the power supply shut down An I O module in the base which has shorted is a possibility 4 Power budget 5V for the CPU has been exceeded If the voltage to the power supply is not correct the PLC may not operate properly or may not operate at all Use the following guidelines to correct the problem WARNING To minimize the risk of electrical shock always disconnect the system power before inspecting the physical wiring 1 First disconnect the external power 2 Verify that all external circuit breakers or fuses are still intact 3 Check all incoming wiring for loose connections If you re using a separate termination block check those connections for accuracy and integrity 4 lf the connections are acceptable reconnect the system power and verify the voltage at the CPU power input is within specification If the voltage is not correct shut down the system and correct the problem 5 If all wiring is connected correctly and the incoming power is within the specifications the PLC internal supply may
14. Maintenance and Troubleshooting In This Chapter Hardware Maintenance Diagnostics CPU Indicators O Module Troubleshooting Noise Troubleshooting Machine Startup and Program Troubleshooting 9 2 Maintenance and Troubleshooting Hardware Maintenance Standard A routine maintenance check about every one or two months or your PLC and Maintenance control system is good practice an should include the following items e Air Temperature Check the ambient air temperature in the control cabinet so the operating temperature range of any component is not exceeded e Air Filter If the control cabinet has an air filter clean or replace it periodically as required e Memory Backup Battery Make sure the CPU memory backup battery does not become completely discharged The CPU uses the same battery indicator to signal a low CPU battery and if applicable a low memory cartridge battery Make sure you have correctly diagnosed which battery is requiring replacement e Fuses or breakers verify that all fuses and breakers are intact e DL405 Module Air Vents verify that all air vents of the CPU and all I O modules are clear allowing air to circulate for cooling CPU Battery The CPU battery is used to retain program V memory and the system parameters Replacement The life expectancy of this battery is five years NOTE Before replacing your CPU battery you should back up your V memory and system pa
15. Outputs are 1 1 OFF X10 Pi C Status on final scan EnD X0 X2 pa Q X1 X3 X4 1 1 X10 Pi E gt Gs TEST RUN to TEST PGM X0 X2 pi gt X1 X3 Wi Hold YO ON X10 Y1 C Let Y1 turn Pa OFF ED You can use AUX 58 on the Handheld Programmer to select the action for each individual output fe o O OO cc OH 52 Fa es oo SF ko c os DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 9 21 Run Time Edits The DL440 and DL450 CPUs allow you to make changes to the application program XIJ Vv during Run Mode These edits are not bumpless Instead CPU scan is 430 440 450 momentarily interrupted and the outputs are maintained in their current state until the program change is complete This means if the output is off it will remain off until the program change is complete If the output was on it will remain on WARNING Only authorized personnel fully familiar with all aspects of the application should make changes to the program Changes during Run Mode become effective immediately Make sure you thoroughly consider the impact of any changes to minimize the risk of personal injury or damage to equipment There are some important operations sequence changes during A OL_ N Run Time Edits 1 If there is a syntax error in the new instruction the CPU will not enter the Run Mode 2 Ifyou delete an output coil reference and the outp
16. T to accept ENT 7 If you press ENT the change is accepted ORN X 0006 and the next address is displayed If you pressed CLR the current address is displayed DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting Special Debug There are several instructions that can be used to help you debug your program Instructions during machine startup operations END PAUSE STOP and BREAK END Instruction You can quickly disable part of the program by inserting an END statement prior to the portion that should be disabled The CPU assumes that is the end of the program The following diagram shows an example Normal Program New END disables X10 and Y1 XO X2 YO XO X2 YO C CD X1 X3 X4 X1 X3 X4 X10 Y1 CD ED X10 Y1 Eno gt ED PAUSE Instruction This instruction provides a quick way to allow the inputs or other logic to operate while disabling selected outputs The output image register is still updated but the output status is not written to the modules For example you could make this conditional by adding an input contact or CR to control the instruction with a switch or a programming device Or you could just add the instruction without any conditions so the selected outputs are always disabled Normal Program PAUSE disables YO and Y1 XO X2 YO YO Y1 CO mp PAUSE AI i ee xa xo x2 YO 1 y C D X1
17. and accumulator stack The following diagram shows an example X2 LD Constant 3 2 4 5 Ko245 Current Acc value Load the value 3245 Acc 0 0 0 0 3 2 4 5 into the accumulator V701 V700 Previous Acc value Acc XIXIXIXIXIXIXIX LD Constant 5 115 1 Accumulator Stack K5151 Curona eae Level1 o 0 0 0 3 2 4 5 V703 V702 aaloe olshi Level2 X X X X X X X X V705 V704 Load the value 5151 into the Co accumulator pushing the value V701 V700 Level3 X X X X X_X_ X X V707 V706 1234 onto the stack Level4 X X X X X X X X V71 V710 Previous Acc value Levels X X xX x x x x x V713 V712 Acc 0 0 0 0 3 2 4 5 Level6 X X X X X X X X V715 V714 C Level X X X X X X X X V717 V716 Level8 X X X X X X X X V721 V720 BREAK X2 Stops Scan Here Cc Restarts Scan Here In the example input X10 triggers the BREAK instruction The CPU will stop scanning the program at this point Now you could easily see how the program instructions have affected the accumulator or accumulator stack The following diagram shows how you could use the Handheld to examine the accumulator stack Select the location to monitor CLR V 2 5 0 0 WDST C V 0703 V 0702 V MON XXXX 3245 Va
18. dder Representation XO X2 X5 YO PEC D x1 X3 X4 oe 1 1 Change X5 X6 Va ED Identify the Instruction ADDRESS INSTRUCTION DESCRIPTION 0 STR XO Starts branch 1 with XO 1 OR X1 Joins X1 in parallel with XO F AND X5 Sak branch 4 with X5 6 END Ends the program FIND the Address AND X N 5 FIND SEARCHING fe Z o OO cc oa 52 Fa esa oo SF ko ta oO Change the Instruction AND X IN 10 ENT WANT TO ALTER Press CLR to abort the edit or ENT to accept ENT If you press ENT the change is accepted ORN X 0006 and the next address is displayed If you pressed CLR the current address is displayed DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting Inserting an Inserting an instruction during Run Mode works almost exactly the same as it does Instruction During during Program Mode Remember INSERT adds an instruction before the Run Mode instruction that is being displayed and the remaining addresses increment Ladder Representation XO X2 X5 X7 YO ao our X1 X3 X4 1 4 Add X7 X6 Va GD Identify the Instruction ADDRESS INSTRUCTION DESCRIPTION 0 STR XO Starts branch 1 with XO 1 OR X1 Joins X1 in parallel with XO Insert before 6 AND X5 Starts branch 4 with X5 AND X7 Adds X7 in series with X5 7 ORN X6 Joins X6 NOT in parallel 10 EN
19. disable SP53 Math Table pointer SP73 Overflow relay SP132 Module busy relay relay DL440 error Slot 5 SP27 Selective I O update SP54 Communication error SP75 Data error relay SP133 Communication error disable relay DL440 relay Slot 5 SP30 Dipswitch 1 status SP56 Table instruction SP76 Load zero relay SP134 Module busy relay relay overrun relay Slot 6 SP31 Dipswitch 2 status SP135 Communication error relay relay Slot 6 SP32 Dipswitch 3 status SP136 Module busy relay relay Slot 7 SP33 Dipswitch 4 status SP137 Communication error relay relay Slot 7 DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 1 O Module Codes Each system component has a code identifier This code identifier is used in some of the error messages related to the I O modules The following table list these codes Code Component Type Code Component Type Hex Hex 01 CPU 21 8 pt Input 02 Expansion Unit 28 16 pt Output FL series Analog Output 03 I O Base 2B 16 pt Input FL series Analog Input Interrupt 11 DCM All CoProcessor 30 32 pt Output Modules DL series Analog Output 12 Remote Master 3F 32 pt Input Slice Master DL series Analog Input 18 High Speed Counter 7F Abnormal Magnetic Pulse Input 20 8 pt Output FF No module detected The following diagram shows an example of how the I O module codes are used PWR E W BATT RUN C O
20. e CPU will not enter the run mode the RUN indicator is off the problem is Viviv usually in the application program unless the CPU has a fatal error in which case the 430 440 450 CPU LED should be on e If you are attempting to enter the run mode by a programming device and the CPU will not enter the run mode first make sure the key switch is inthe TERM position and then try to enter the run mode e If you are using the keyswitch to change to RUN mode and the CPU does not respond attach a programming device to diagnose what error is being returned e If the indicator is flashing the CPU is in firmware upgrade mode Both of the programming devices handheld programmer and DirectSOFT will return a error message and depending on the error may also recommend an AUX function to run that will aid in further diagnosing the problem The most common programming error is Missing END Statement All application programs require an END statement for proper termination Appendix B lists all the error codes aoueUaIUle sed J a x oe S D 2 7 e e J Q DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting CPU Indicator If the CPU indicator is on a fatal error has occurred in the CPU Generally this is not Vivi Vv a programming problem but an actual hardware failure You can power cycle the 430 440 450 system to clear the error If the error clears the system should be clos
21. ely monitored and every effort should be made to try to determine the cause of the problem You will find this problem is sometimes caused by high frequency electrical noise introduced into the CPU from a outside source Check your system grounding and install electrical noise filters if the grounding is suspected If power cycling the system does not reset the error or if the problem returns replace the CPU BATT Indicator If the BATT indicator is on or flashing either or both the CPU Memory Cartridge Vivi Vv batteries are low 2 5V or less The DL430 does not have a memory cartridge The 430 440 450 battery voltage is continuously monitored while the system voltage is being supplied BATT LED Status Error Condition Flashing at 2Hz CPU baitery is low Flashing at 0 5 Hz Memory Cartridge battery is low ON constantly Both the CPU and Memory Cartridge batteries are low Procedures for how to replace either of the batteries can be found in the Hardware Maintenance section earlier in this chapter DIAG Indicator The diagnostics indicator is normally off It turns on if the CPU detects a failure of its XTX Vv run time diagnostics Extreme electrical noise may cause a diagnostics failure so 430 440 450 power cycle the CPU first If the DIAG indicator still turns on the CPU is probably faulty Replace it with a known good one to be sure I O Indicator If this indicator is on a
22. he problem is corrected the indicators will reset An I O error will not cause the CPU to switch from the run to program mode however there are special relays SPs available in the CPU which will allow this error to be read in ladder logic The application program can then take the required action such as entering the program mode or initiating an orderly shutdown The following figure shows a example of the failure indicators PWR BATT Loose terminal block RUN MSLV O LED indicator ay CPU E ECOM Jre of i shen ie Internal diagnostics O V7756 0201 Major Error Code A V7760 0003 Error Location Base 00 Slot 03 V7762 0201 Module Error Code See lo SP45 Ff IO Error A ijpmam a ae AUX 42 1 0 BASE 0 SLOTS Loose terminal block E201 TERMINAL BLOCK OFF COM Indicator The COM indicator on DL430 and DL440 CPU turns ON when the CPU has detected Viv xX a communication error on one of the two communication ports built into the CPU 430 440 450 The most common causes for this error are e The cable is disconnected e The cable has a broken wire or has been wired incorrectly e The cable is improperly terminated or grounded e The device connected to the port is sending data incorrectly sed
23. licate references are found NOTE You can use the same coil in more than one location especially in programs that use the Stage instructions and or the OROUT instructions The Duplicate Reference check will find these outputs even though they may be used in an acceptable fashion D Z S o oO OO cc OH 52 To es oo Ske D c os DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting 9 19 TEST PGM and Test Mode allows the CPU to start in TEST PGM mode enter TEST RUN mode run TEST RUN Modes afixed number of scans and then return to TEST PGM mode You can select from 1 to 65 535 scans You can select this operation from either the Handheld Programmer AUX 12 or DirectSOFT via a PLC Modes menu option With the Handheld the actual mode entered when you first select Test Mode depends on the mode of operation at the time you make the request If the CPU is in RUN mode then TEST RUN is entered If the mode is PGM then TEST PGM is entered DirectSOFT provides more flexibility in selecting the various modes with different menu options The following example shows how you can use the Handheld to select the Test Modes Use AUX 12 to enter Test Mode AUX 1 2 ENT ENT MODE TEST PGM To specify the number of scans CLR 1 SHFT TEST NO OF SCANS CPU runs scans and returns to Test PGM To switch to TEST PGM m
24. ll through the messages Use AUX 5C to view the tables CLR AUX 5 SHFT C ENT m AUX 5C SHOW ERR MSG ERR OR MSG sad J Q 5 OS c3 co 05 nD 33 O0 a Co Arrow key selects Errors or Messages SHFT ENT e AUX 5C SHOW ERR MSG ERR OR MSG Example of a message display PUMP 3 FAILED 04 22 93 17 30 00 DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting System Error Codes X Viv 430 440 450 fe Z o OO cc OO 52 Fa es oo SF ko ta oO The System error log contains 32 of the most recent errors that have been detected The errors that are trapped in the error log are a subset of all the error messages which the DL405 systems generate The following errors are captured in the System error log upon first detection or reoccurrence Error Description Error Description Code Code E003 Software time out E155 RAM failure E004 Invalid instruction E201 Terminal block missing RAM parity error in the CPU E041 CPU battery low E202 Missing I O module E043 Memory cartridge battery low E203 Blown fuse E099 Program memory exceeded E206 User 24V power supply failure E101 CPU memory cartridge missing E250 Communication failure in the I O chain E104 Write fail E251 I O parity error E151 Invalid Command E252 New
25. ll when an error occurs the oldest error is pushed erased from the table and the new error is inserted in the row The following diagram shows an example of a the Fault Message table as shown in DirectSOFT You can access the error code table and the message table through DirectSOFT s PLC Diagnostic sub menus Details on how to access these logs are provided in the DirectSOFT manual Error Msg Example Messages oo Most recent message CIZA 10 23 45 92 NEW MESSAGE appears here not at 35702721 10 23 46 23 NEW MESSAGE 95 02 21 10 23 46 52 NEW MESSAGE the top of the table 95 02 21 10 23 46 84 NEW MESSAGE 95 02 21 10 23 47 20 NEW MESSAGE 95 02 21 10 23 02 11 OLD TEST MESSAGE 95 02 21 10 23 02 32 OLD TEST MESSAGE N ill A 95702721 10 23 02 53 OLD TEST MESSAGE 95 02 21 10 23 02 76 OLD TEST MESSAGE ext message w 95702721 10 23 02 98 OLD TEST MESSAGE show up In this row 95 02 21 10 23 03 20 OLD TEST MESSAGE which is now the OR INDI94 1N 99 NF 49 NIN TCCT MOCCACC L E You cannot view the entire table at one time with the handheld programmer Instead the messages automatically appear on the handheld programmer display as they occur The message will remain on the display as long as the Fault instruction is being executed The following examples show you how to use the Handheld and AUX Function 5C to show the error codes The most recent error or message is always displayed You can use the PREV and NXT keys to scro
26. lue is displayed When you use the Handheld to return to Run Mode the CPU starts scanning the program at the rung following the BREAK DL405 User Manual 4th Edition Rev A
27. n Rev A Maintenance and Troubleshooting 9 3 CMOS RAM The CMOS RAM Memory Cartridge battery is used to maintain the contents of the Memory Cartridge Memory Cartridge RAM when the power is turned off The life expectancy of this Battery battery is three years Replacement NOTE For added security you will want to save the contents of the memory sae cartridge to either another memory cartridge cassette tape or computer disk to avoid losing the contents of the memory cartridge when the battery is removed The memory cartridge does however have a built in capacitor to retain the memory for several minutes while the battery is being replaced If the system has been powered off you should power up the CPU with the memory cartridge installed for at least 5 seconds prior to changing the battery This is done to ensure the capacitor used to maintain the proper voltage levels necessary to retain memory is fully charged WARNING Never remove the Memory Cartridge from the CPU when the CPU is powered up If the memory cartridge is removed while under power the memory cartridge may become unreliable Do not attempt to recharge the battery or dispose of it by fire The battery may explode or release hazardous materials wee OZD TENA To remove the CMOS RAM Memory Cartridge battery 1 Power down the CPU 2 Remove the memory cartridge from the CPU by gently pulling the lever down till the cartridge is l
28. nd CPU Status Relays System Monitoring Accumulator Communication Real time Relays Relays Status Relays Monitoring Relays SPO First scan relay SP11 Forced run mode SP40 Critical error relay SP60 Value less than relay SP120 Module busy relay relay Slot 0 SP1 Always ON relay SP12 Terminal run mode SP41 Warning relay SP61 Value equal to relay SP121 Communication error relay relay Slot 0 SP3 1 minute relay SP13 Test run mode relay SP43 Battery low relay SP62 Value greater than SP122 Module busy relay relay Slot 1 SP4 1 second relay SP14 Break relay 1 SP44 Program memory SP63 Zero relay SP123 Communication error o error relay relay Slot 1 ok SP5 100 millisecond relay SP15 Test program mode SP45 I O error relay SP64 Half borrow relay SP124 Module busy relay 4 relay Slot 2 la fat SP6 50 millisecond relay SP16 Terminal program SP46 Communications error SP65 Borrow relay SP125 Communication error Cc 3 mode relay relay relay Slot 2 oo SP7 Alternate scan relay SP17 Forced stop mode SP47 I O configuration error SP66 Half carry relay SP126 Module busy relay D w relay relay Slot 3 p g oxo SP21 Break relay 2 SP50 FAULT instruction SP67 Carry relay SP127 Communication error oo relay relay Slot 3 m SP22 Interrupt enabled SP51 Math timeout relay SP70 Sign relay SP130 Module busy relay co relay Slot 4 SP25 CPU battery disabled SP52 Grammatical error SP71 Pointer reference SP131 Communication error relay relay error relay Slot 4 SP26 I O update
29. ne device to another Ground metal enclosures around the system A loose wire is no more than a large antenna waiting to introduce noise into the system therefore you should tighten all connections in your system Loose ground wires are more susceptible to noise than the other wires in your system Review Chapter 2 Installation and Safety Guidelines if you have questions regarding how to ground your system e Electrical noise can enter the system through the power source for the CPU and I O Installing an isolation transformer for all AC sources can correct this problem DC sources should be well grounded good quality supplies Switching DC power supplies commonly generate more noise than linear supplies e Separate input wiring from output wiring Never run analog I O wiring or low voltage discrete I O wiring close to high voltage wiring e To improve noise immunity you may optionally install the factory provided shunt between logic ground LG and chassis ground G on the CPU terminal strip shown to the left e In rare instances you may want to isolate logic ground from chassis fe Z o OO cc oa 52 Fa es oo SF ko ta S D gt ground There is a single jumper on the 4 slot base and two jumpers on O the 6 and 8 slot bases for this purpose Isolation can be obtained by CS removing these jumper s shown below Spring loaded securing screw
30. ode CLR 2 SHFT TEST STOP SCAN ENT to confirm the return to TEST PGM To switch to TEST RUN mode CLR 3 SHFT TEST START SCAN ENT to confirm the entry of TEST RUN o 2a fe z o gt fe fe 5 Co With the Handheld Programmer you gain some advantages by using Test Mode e The Handheld Programmer status displays are more detailed e You can enable the CPU to hold output states Test Mode Displays For some instructions the TEST RUN mode display is more detailed than the status displays shown in RUN mode The following diagram shows an example of a Timer instruction display during TEST RUN mode RUN Mode TEST RUN Mode aoueUajUle T 000 K0500 Current Value DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting Holding Output States In normal RUN mode the outputs are turned off when you return to PGM mode In TEST RUN mode you can set each individual output to either turn off or hold its last output state on the transition to TEST PGM mode The ability to hold the output states is especially useful since It allows you to maintain key system I O points for examination The following diagram shows the differences between RUN and TEST RUN modes RUN Mode to PGM Mode X0 X2 Tk C X1 X3 X4
31. oosened then pull the lever straight out 3 Remove the cover retaining screw 4 Lifttop cover off lifting ata slight tilt to avoid breaking the guides beside the connector 5 Grasp battery and lift straight up To install the CMOS RAM Memory Cartridge battery 1 Align the battery leads to the keyed holes in the circuit board 2 Press the battery flush with the circuit board 3 Place cover back on module using a slight tilt to catch the guides beside the connector 4 Install the cover retaining screw 5 Note the date the battery was changed soueusjUule sed J a e 2 D 2 7 e e J Q Replace battery with part D4 MC BAT DL405 User Manual 4th Edition Rev A 9 4 Maintenance and Troubleshooting Diagnostics Diagnostics DL405 performs over 90 pre defined diagnostic routines with every CPU scan The diagnostics have been designed to detect failures for the CPU local base and local expansion bases These detected errors cover the following CPUs expansion units I O bases communication modules memory cartridges and batteries There are two primary error classes fatal and non fatal Fatal Errors Fatal errors are errors the CPU has detected that offer a risk of the system not functioning safely or properly They will either cause the CPU to change from RUN mode to PROGRAM or will disallow changing from PROGRAM mode to RUN mode If the fatal error is detected while in PRO
32. ot operate normally then test for a module causing the problem by following the steps below e Turn off power to the CPU e Remove the CPU from the base leaving its power cord attached e Reapply power to the CPU Ifthe PWR LED operates normally the problem is most likely in one of the modules in the local CPU base To isolate which module is causing the problem remove one module at atime until the PWR LED operates normally Put the CPU back in the base prior to testing for a bad module Follow the procedure below e Turn off power to the CPU e Remove a module from the base e Reapply power to the CPU Bent base connector pins on the module can cause this problem so check the connector Remember that exceeding the power budget is a common error that will cause the PWR indicator to not come on or to come on intermittently Power budgeting problems usually appear during system start up rather than after a long period of operation If there is any doubt it s a good idea to recheck this WARNING The PLC may reset if the power budget is exceeded If there is any X Z doubt about the system power budget please check it at this time Exceeding Loni the power budget can cause unpredictable results which can cause damage and injury Verify the modules in the base operate within the power budget for the chosen base You can find these tables in Chapter 4 System Design and Configuration Run Indicator If th
33. problem in the local expansion or remote I O chain has been Viviv detected Any of the problems listed below could be the cause of the I O LED being 430 440 450 on e A blown fuse inside an I O module e A loose terminal block e The 24 VDC supply has failed e The module or Expansion unit has failed e The I O configuration check detects a change in the I O configuration I O error detection for remote I O will be covered in the DL405 Remote and Slice I O manual To aid you in further diagnosing where the I O error is each I O module has LEDs to indicate if an error is present The discrete I O modules covered in this manual may have a combination of the following I O indicators fe Z o OO cc oa 52 Fa es oo SF ko ta oO Indicator Error condition TB Loose or missing terminal block 24V External 24V power supply not providing the correct voltage FU Module fuse has blown check the I O modules specification sheets to see if the fuse is replaceable Many other specialty modules also have indicators The manuals for those products contain information on the indicators and status LEDs DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting If the modules are not providing any clues to the problem run AUX 42 from the handheld programmer or I O diagnostics in DirectSOFT Both options will provide the base number the slot number and the problem with the module Once t
34. r Display example 8 E401 MISSING END TMRA T 002 K00050 aoueUalUle shows location in question o 2a fe z o gt fa 5 Co Syntax OK display NO SYNTAX ERROR If you get an error see the Error Codes Section for a complete listing of programming error codes Correct the problem and continue running the Syntax check until the NO SYNTAX ERROR message appears DL405 User Manual 4th Edition Rev A 9 18 Maintenance and Troubleshooting Duplicate You can also check for multiple uses of the same output coil Both programming Reference Check devices offer a way to check for this condition For example you can AUX 21 CHECK PROGRAM to check for duplicate references from a Handheld Programmer or you can use the PLC Diagnostics menu option within DirectSOFT The following example shows how to perform the duplicate reference check with a Handheld Programmer Use AUX 21 to perform syntax check AUX 2 1 ENT ENT AUX 21 CHECK PROGRAM 1 SYN 2 DUP REF Select Duplicate Reference check 2 _ ENT This may take a minute or so e BUSY One of two displays will appear Error Display example 12 E471 DUP COIL REF OUT Y 0000 shows location in question Syntax OK display NO DUP REFS If you get a Duplicate Reference error correct the problem and continue running the Duplicate Reference check until no dup
35. rameters This can be done by saving the V memory and system parameters to either a Memory Cartridge or to cassette tape or by using DirectSOFT to save the program to hard floppy disk on a personal computer To prevent memory loss the CPU battery can be changed while the system is powered up If the CPU has been powered off you should power up the CPU for at least 5 seconds prior to changing the battery This is done to ensure the capacitor used to maintain the proper voltage levels necessary to retain memory is fully D charged 88 D S To replace the CPU battery To O e Pull the battery out from the battery retaining clip 29 k 5 e Lift the clip on the two wire battery connector 7O pees tk gE n O O e Slide the battery connector apart e J He To install the CPU battery he e Join the keyed battery connector so the red wires 1 Ce match Ae e Push gently till the connector snaps closed E e Slide the battery into the battery retaining clip till the battery lies flush in the opening e Note the date the battery was changed Replace battery with part D3 D4 BAT WARNING Do not attempt to recharge the battery or dispose of it by fire The battery may explode or release hazardous materials wt OZD mas DL405 User Manual 4th Editio
36. se input signals can be generated when the leakage current of an output device is great enough to turn on the connected input device To correct this install a resistor in parallel with the input or output of the circuit The value of this resistor will depend on the amount of leakage current and the voltage applied but usually a 10K to 20K ohm resistor will work Verify the wattage rating of the resistor is correct for your application e The fuse blown indicator on a output module will indicate a problem only if an output point is connected to a load and the point is turned on This indicator works by sensing a voltage drop across the fuse so there must be a voltage applied to the fuse and a load applied to the output to create the voltage drop before it can be reported by the module e The easiest method to determine if a module has failed is to replace it if you have a spare However if you suspect another device to have caused the failure in the module that device may cause the same failure in the replacement module as well As a point of caution you may want to check devices or power supplies connected to the failed module before replacing it with a spare module fe Z o OO cc oa 52 Fa es oo SF ko ta oO DL405 User Manual 4th Edition Rev A Testing Output Points T Handheld Programmer Keystrokes Used to Test an Output Point Maintenance and Troubleshooting ES Output points can be set on
37. statement H C at the beginning of the X1 X3 x4 Program This disables 1 the remainder of the o program a X10 Y1 z C zS Me 3 Do E 2a fe From a clear display use the following keystrokes ga Y OUT 0 BITST Y 10 Y 0 16P MON Turn the output on or off YO is now on Y OUT 0 SHFT ON Y 10 Y 0 16P MON DL405 User Manual 4th Edition Rev A Maintenance and Troubleshooting Noise Troubleshooting Electrical Noise Noise is one of the most difficult problems to diagnose Electrical noise can enter a Problems system in many ways which are divided into two categories conducted or radiated e Conducted noise is when the electrical interference is introduced into the system by way of an attached wire panel connection etc It may enter through an I O module a power supply connection the communication ground connection or the chassis ground connection e Radiated noise is electrical interference introduced into the system through the air as radio waves without a direct electrical connection Reducing The following tips can help reduce electrical noise enough for normal operation Electrical Noise e Most noise problems result from improper grounding of the system A good earth ground can be the single most effective way to correct noise problems If a ground is not available install a ground rod as close to the system as possible Ensure all ground wires are single point grounds and are not daisy chained from o
38. ut was on at the time the output will remain on until it is forced off with a programming device 3 Input point changes are not acknowledged during Run Time Edits So if you re using a high speed operation and a critical input comes on the CPU may not see the change You can use either the Handheld Programmer or DirectSOFT to edit the program during Run Mode The following pages show a brief example of how to do this with the Handheld Programmer You use AUX 14 to edit the program during Run Mode We ve already shown you how to select the various AUX functions but a few things are different with AUX 14 e Once you select AUX 14 the Handheld RUN LED starts blinking This indicates the a Run Mode edit is in progress e If you had displayed an address just before selecting AUX 14 that address will automatically appear So you can search for an address or instruction before you select AUX 14 or after you select AUX 14 Select AUX 14 Run Time Edit AUX 1 4 ENT L AUX 1 OPERATING MODE a AUX 14 RUN TIME EDIT 5 Sg 03 Press ENT to select AUX 14 and display the address 2 ENT oko Ho 5 Q DL405 User Manual 4th Edition Rev A 9 22 Maintenance and Troubleshooting Changing an Once you ve found the instruction you can change it very easily The following Instruction During example shows you how to change the X5 contact to X10 Run Mode La
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